2008 Cobalt | Cobalt, G5 VIN A Service Manual | Document ID: 2371867 #09-06-01-014: Oil Leak by High Pressure Fuel Pump (Reseal Camshaft Cap) - (Dec 3, 2009)

Subject: Oil Leak by High Pressure Fuel Pump (Reseal Camshaft Cap)

Models: 2007-2009 SS, HHR SS 2007-2009 GXP 2007-2009 Redline 2008-2009 GT 2008 Daewoo G2X Equipped with a RPO LNF Engine Please Refer to GMVIS

Condition

Some customers may comment on an oil leak.

Upon further investigation, a technician may find oil leaking from the high pressure fuel pump area.

Cause

This condition may be caused by a camshaft cap that is not sealed correctly to the cylinder head, causing oil to leak out.

Correction

1. Verify the customer's concern. 2. Remove the fuel pump. Refer to Fuel Pump Removal in SI. 3. Remove the camshaft cover. Refer to Camshaft Cover Removal in SI.

4. Remove the camshaft cap (1). Remove all excess sealing material from both surfaces.

Note: It is critical during installation to ensure the bearing rear cap and cylinder head alignment is correct and the mating surfaces are flush. © 2020 . All rights reserved. https://gsitlc.ext.gm.com/gsi/showDoc.do?pubName=Cobalt,%20G5%20VIN%20A%20Service%... 9/23/2020 ◦ Ensure that all sealing material has been removed from the components and the sealing surfaces are clean and free of contamination prior to applying the sealer. ◦ Install and align the rear cap within 20 minutes of applying the sealer. 5. Apply a 2.5 mm (0.1 in) bead of sealer, GM P/N 12378521 (in Canada, use P/N 88901148) to the cylinder head at the number 6 intake camshaft rear cap mating surface. Note: Apply the sealer to all locations centrally locating the bead on the rail. ◦ Run the bead to 5 mm (0.2 in), dimension “a”, as shown. ◦ Where the cap ends on the perimeter rail, extend bead approximately 4 mm (0.2 in) beyond edge of cap. ◦ Run bead, dimension “c”, 32 mm (1.3 in) from the edge of the cylinder head as shown. ◦ Run bead, dimension “b”, 20 mm (0.8 in) from edge of cylinder head as shown. 6. Install the number 6 intake camshaft rear cap. 6.1. Tighten the cap bolts evenly to 5 (44 lb in). 6.2. Tighten the cap bolts evenly to 10 (89 lb in). 6.3. Back the cap bolts out 120 degrees. 6.4. Tighten the cap bolts evenly a final pass to 10 (89 lb in). 7. Install the camshaft cover and gasket, GM P/N 12609291. Refer to Camshaft Cover Installation in SI. 8. Install the fuel pump. Refer to Fuel Pump Installation in SI. Important: When installing the fuel pump, install a NEW high pressure fuel pump O-ring (GM P/N 12600313), high pressure fuel pump gasket-to-cylinder head (GM P/N12595951) and high pressure fuel pipe (GM P/N12615401).

Parts Information

Part Number Description

12609291 Camshaft Cover Gasket

12595951 Gasket, High Pressure Fuel Pump Gasket

12600313 High Pressure Fuel Pump O-Ring

12615401 High Pressure Fuel Pipe

12378521 (U.S.) Silicone 88901148 (Canada)

Warranty Information

For vehicles repaired under warranty, use:

Labor Operation Description Labor Time

J7549* Reseal Camshaft Cap 2.6 hrs

*This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur WE SUPPORT on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety VOLUNTARY instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your TECHNICIAN vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information. CERTIFICATION

© 2020 General Motors. All rights reserved. https://gsitlc.ext.gm.com/gsi/showDoc.do?pubName=Cobalt,%20G5%20VIN%20A%20Service%... 9/23/2020